Wire Drawing

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PRESENTATION ON WIRE DRAWING .

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CONTENTS.• 1.INTRODUCTION.• 2.PROCESS.• 3.TYPES OF MACHINE.• 4.LUBRICATION.• 5.DRAWING DIES.• 6.EQUIPMENT & TOOLS.• 7.GENERAL FEAUTURES.• 6.IMPORTANTS OF PLC.• 7.Defects• 8.CONCLUSION.



INTRODUCTION.• 1.WIRE DRAWING IS A METAL WORKING

PROCESS USED TO REDUCE THE CROSS SECTION AREA OF WIRE.

• 2.THE PRODUCT MAY BE ELECTRICAL WIRING, CABLES,TENTION-LOADED STRUCTURE COMPONENTS ETC.



Drawing Process.• 1.PROCESS IS QUIT SIMPLE IN CONCEPT.

• 2.AT FIRST WIRE IS SHRINKING .THE BEGING OF IT BY HAMERING FILING,ROLLING OR SWAGING THAT IT WILL FIT THROUGH THE DIA.

• 3.THEN IT IS PULLED THROUGH THE DIA.

• 4.IT REQUIRE MORE THANE ONE STEP TO PRODUCE ONE TYPE

• 5.In this process the cross section of wire is reduced by pulling it through a die.

• 6.Die angle has great influence on the drawing force and the quality of the drawn product

7.Drawing FORCE : F = Yavg Af In (Ao/Af) ; Yavg – average true stress of the material

in the die gap



TYPES OF WIRE DRAWING MACHINETHERE ARE VARIOUS TYPE OF WIRE DRAWING MACHINE BUT THE BASIC TYPES ARE -1.SINGE STEP2.CONTINUOUS WIRE DRAWING.

1.SINGE STEP MACHINE. 2.CONTINUOUS WIRE DRAWING MACHINE.



LUBRICATION DURING WIRE DRAWING

PRORER LUBRICATION IN THE DWARING PROCESS IS VERY NECESSARY FOR SMOOTH SURFACE FINISH AND LONG DIA LIFE.

TYPES OF LUBRICATION---1.WET DRAWING.2.DRY DRAWING.3.METAL COATING.4.ULTRASONIC VIBRATION.

TYPES OF LUBRICATS-1.OIL.2.CUPPER SULFATE SOLUTIONETC



CONCEPT OF DIE.



DIE MATERIALS.• 1.TUNGSTEN CARBIDE:Lowest cost,shock

resistance,large sizes available,lower life epectancy.USED-for steel wire drawing.

• 2.NATURAL DIAMONDS:Wear resistance,gives excellent wire surface,high thermal conductivity,longer life expectancy,limited availability in required high quality &quantity.

• 3.SYNTHETIC SINGLE CRYSTAL:Consistently uniform material,gives excelent wire surface,high thermal conductivity,larger size ranges are still costly at this time.

• 4.POLY CRYSTALLINE DIAMOND:Excels in life expectancy,wear resistance of diamond,shock resistance of carbide,high availability,cost effectiveness,high drawing force,smaller fines requires more filtration,may be damaged by temp.above 700c,wire surface condition less than from natural dimond.



Equipment and tools.1.POINTERS:Pointers as the name implies

is used to put a taper (or point on the start

end of the wire so that it can be threaded

through the die.

2.PULL IN DOGS: Pull in dogs are used to

grip the wire end as it comes through the

die and once the dog is fastend to the block

the wire can be pulled through the die and

will then wrap round the block.

3. BUTT WELDERS:Butt welders Are used

to join wire ends. BUTT WELDERS . .

PULL IN DOGS. POINTERS.



GENERAL FEAUTURES.• 1.DRAWING BLOCKS.• 2.MAIN BLOCK FRAME.• 3.TRANSMISSION.• 4.MAIN MOTORS.• 5.SENSOR ARMS.• 6.DIEBOXES.• 7.SAFETY GUARDS.• 8.WATER COOLING &• VENTILATION.• 9.ELECTRICAL• EQUIPMENT.



IMPORTANCE OF PLC IN WIRE DRAWING WORKS.

1.PROVIDE CONSTANT SPPED OF MOTOR.

2.MAINTAIN CONSTANT DRAWING FORCE.(IMPORTANT)

3.WE CAN GET VARIOUS AWG WIRE FROM A SAME MACHINE BY CHANGING THE PROGRAMME OF PLC.

4.VERY HIGH ACCURACY.

5,SAVING IN LABOUR COST.AND MANY MORE



Defects in DrawingA number of defects in drawing can occur, which include:

(a) Wrinkling in the flange occurs due to compressive buckling in the circumferential direction (blank holding force should be sufficient to prevent buckling from occurring).

(b) Wrinkling in the wall takes place when a wrinkled flange is drawn into the cup or if the clearance is very large, resulting in a large suspended (unsupported) region.

(c) Tearing occurs because of high tensile stresses that cause thinning and failure of the metal in the cup wall. Tearing can also occur in a drawing process if the die has a sharp corner radius.

(d) Earring occurs when the material is anisotropic, i.e. has varying properties in different directions.

(e) Surface scratches can be seen on the drawn part if the punch and die are not smooth or if the lubrication of the process is poor.



Defects in Drawing



CONCLUSION.

Drawing provide ways to form

shapes with uniform cross

sections at high production rates.


Wire Drawing

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